Heat Exchanger with Direct Flow Path Modules

ABSTRACT

A heat exchanger including an inlet tank with an internal manifold space and a plurality of modules including a core having a plurality of tubes. The modules are in fluid communication with the inlet tank and the tubes terminate inside the manifold space so that a cooling media can flow in a direct path from the manifold space into the tubes.

TECHNICAL FIELD

The present disclosure relates to heat exchangers, and more particularly to modular heat exchangers.

BACKGROUND

Machine and engine systems include a variety of heat exchangers to cool components, fluids, and air. Such heat exchangers include, for example, engine radiators and air-to-air aftercoolers (ATAAC) associated with a turbocharger. These heat exchangers include a core with a plurality of tubes to pass a cooling media through and fins to help dissipate heat.

The use of a modular heat exchanger may improve maintenance and manufacturability issues. An example of a modular radiator is described in U.S. Pat. No. 5,137,080 (the '080 patent). Modular radiators include a plurality of heat exchanger modules. During maintenance, only damaged modules may have to be replaced, saving time and money. The modules shown in the '080 patent include small mini-tanks or module tanks attached to each end of the core. The module tanks are used to direct flow and form a seal between the modules and an inlet or outlet tank.

The need for module tanks, however, may limit the applicability of modular heat exchangers. The module tanks restrict flow and cause a pressure drop of the cooling media as it passes in an indirect path; into the inlet tank, through the module tank, through the core, through another module tank, and into the outlet tank. The use of modular heat exchangers may accordingly be limited to applications with sufficient cooling media pressure. The module tanks may also add cost and consume valuable space in a machine where it is used.

The present disclosure is directed to overcoming one or more of the problems set forth above.

SUMMARY

In one aspect, the present disclosure provides a modular heat exchanger through which a cooling media passes. The heat exchanger includes an inlet tank, outlet tank, and a plurality of modules having tubes that terminate in an internal manifold space of the inlet and outlet tanks to allow for a direct flow of the cooling media between the tanks and modules. In another aspect, the inlet and outlet tanks include a first side with a plurality of module apertures for receiving the modules and a seal lip extending from the first side and around the periphery of the module apertures to form a seal between the seal lip and the module.

In yet another aspect, the modules include a core having a first and second end and a header coupled to at least one of the first and second end. In still another aspect, the header includes a base coupled to the core and a boss around a periphery of the base. The boss extends from the base to form a seal between a periphery of the boss and the tank.

Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a heat exchanger including an inlet tank, outlet tank, and modules there between;

FIG. 2 is an enlarged cross-sectional front view from FIG. 1 showing the module and the inlet tank;

FIG. 3 is a cross-sectional top view of the module and inlet tanks shown in FIG. 2; and

FIG. 4 is a diagrammatic illustration of an exemplary engine system using heat exchangers.

DETAILED DESCRIPTION

A heat exchanger 10 includes a wide variety of devices that may involve passing a fluid or cooling media through it to dissipate heat. Such devices may include (but are not limited to) radiators where the cooling media is a liquid or an air-to-air aftercooler (ATAAC) where the cooling media is air. As seen in FIG. 1, the heat exchanger 10 may include an inlet tank 12, an outlet tank 14, and plurality of modules 16.

The modules 16 are installed in fluid communication with the inlet tank 12 and outlet tank 14. As shown, the inlet and outlet tanks 12 and 14 both include a first side 18, second side 20 opposite first side 18, first wall 22, second wall 24 opposite first wall 22, third wall 26, and fourth wall 28 opposite third wall 26 to form a box structure. The modules 16 may be installed in the first side 18 of the inlet and outlet tanks 12 and 14 so that the modules 16 are in fluid communication with the inlet and outlet tanks 12 and 14. In other embodiments, the inlet and outlet tanks 12 and 14 need not form a box structure and may be cylindrical, spherical, or another geometric shape. The modules 16 may also be installed in another side or part of the inlet and outlet tanks 12 and 14.

The inlet tank 12 includes one or more inlets 30 and outlet tank 14 includes one or more outlets 32. The cooling media enters the heat exchanger 10 through inlet 30 and into the inlet tank 12. The cooling media then passes through the modules 16, into the outlet tank 14, and exits through the outlet 32.

FIG. 2 shows the modules 16 coupled or installed to the inlet tank 12 to form a seal. The modules 16 are installed in outlet tank 14 in a similar manner as they are installed in the inlet tank 12. It is also contemplated that the installation of the modules 16 may vary between the inlet tank 12 and the outlet tank 14. For example, modular tanks may be used for the inlet tank 12 and not the outlet tank 14, or visa versa. The modules 16 may be inserted, press fit, caulked, glued, welded or otherwise installed and sealed into the inlet tank and outlet tank 12 and 14.

The inlet and outlet tank 12 and 14 both include an interior space or internal manifold space 34 inside the box structure formed by the walls. Inlet and outlet tank 12 and 14 also include module apertures 36 in the first side 18 to receive modules 16. The module apertures 36 may also be in another side where the modules 16 could be installed. Around the outer perimeter or periphery of the module apertures 36 is a seal lip 38.

The seal lip 38 extends substantially vertically or perpendicular to the first side 18 and into the manifold space 34. The seal lip 38 may also extend away from the manifold space 34 or at any angled orientation from the first side 18. The seal lip 38 may also include an outer surface 40 facing away from the module 16, an inner surface 42 facing toward the module 16, and a seal surface 44 contacting the module 16. In other embodiments, the seal lip 38 may also be formed as part of first wall 22, second wall 24, third wall 26, fourth wall 28, or other surface or structure of the inlet or outlet tank 12 or 14.

The modules 16 include a first end 46 installed in the inlet tank 12 and a second end 48 installed in the outlet tank 14. The modules 16 also include a header 50 at each of the first end 46 and second end 48 and a core 52 extending between the headers 50. The headers 50 may be coupled to the ends of the core 52 via welding, brazing, adhesive, seals, bolts, or other fastening means.

The core 52 includes fins 54 and tubes 56. The tubes 56 are in fluid communication with the inlet and outlet tanks 12 and 14. The tubes 56 extend through the fins 54 and headers 50 and may have tube ends 58 opening and terminating inside the manifold space 34 of the inlet and outlet tanks 12 and 14. The fins 54 may include a plurality of appendages that function to facilitate heat dissipation of the cooling media as it travels through the tubes 56. The appendages may be relatively thin and flat and may form a grid pattern.

As seen in FIGS. 2 and 3, the headers 50 may include a base 60 with tube apertures 62. The tube apertures 62 receive tubes 56. The base 60 may be defined by a perimeter encompassing the tubes 56. Additional structure may be added beyond this perimeter of the base 60.

The headers 50 may also include a boss 64. The boss 64 may extend substantially vertically or perpendicular to the outer perimeter or periphery of the base 60 and into the manifold space 34. In other embodiments, the boss 64 may extend away from the manifold space 34 or extend at an angle that may match the angle of the seal lip 38.

The boss 64 includes an exposed surface 66 and a seal 68. The exposed surface 66 is the portion of the boss 64 open to the manifold space 34. The seal 68 provides the engagement between the module 16 and either the inlet or outlet tank 12 or 14. The seal 68 includes a seal surface 70 facing the seal lip 38. The seal surface 70 may include one or more seal slots 72 around the boss 64. The seal slots 72 may be depressions cut, stamped, or otherwise formed in the boss 64.

The seal 68 may also include one or more seal rings 74 extending around the seal surface 70. In one embodiment, the seal ring 74 is disposed, at least partially, inside the seal slot 72. The seal ring 74 makes contact with the seal lip 38 to form an engagement sufficient to prevent significant leakage of the cooling media passing through the heat exchanger 10. The seal ring 74 may include a rubber o-ring, gasket, rubber or elastic member, caulk, sealant, or other seal-forming component. The seal ring 74 may be circular, square, oval, rectangular, or any other shape in cross-section to achieve a seal. Similarly, the seal slots 72 may be partially circular in cross-section or have another shape to accept the seal rings 74. The seal 68 may include two seal slots 72 and seal rings 74, as seen in FIG. 2. In alternative embodiments, the seal 68 may include more or fewer seal slots 72. Other embodiments include the use of a seal ring 74 without the seal slots 72. The seal 68 may also include any appropriate sealing mechanism. For example, a gasket may be pressed between corresponding overhanging flanges on the modules 16 and outlet and inlet tanks 12 and 14 and may include bolts to help form the seal 68.

In operation, the cooling media enters the inlet tank 12 and into the manifold space 34. From the manifold space 34, the cooling media may enter directly or have a straight line path, direct line of sight, direct flow path, or direct path into each of the tubes 56 in the core 52 of the modules 16 without having to pass into another intermediary structure. Utilizing the direct path configuration, the tube ends 58 of the tubes 56 terminate inside the manifold space 34. Similarly, the cooling media has a direct path from the tubes 56 into the manifold space 34 of the outlet tank 14. The direct path configuration may limit pressure drop and restrictions on the flow of the cooling media as it passes through the heat exchanger 10.

The materials used to construct the inlet tank 12, outlet tank 14, and modules 16 are varied. The materials may include aluminum, copper, brass, steel, plastic, PVC, or any other material capable of withstanding the temperature and corrosive environment the heat exchanger 10 could be exposed to. Material may also be selected for cost, strength, weight, temperature tolerance, heat conductivity properties, and other performance criteria. Individual components may also be constructed of materials different than the other components of the heat exchanger 10. For example, the fins 54 may be constructed from copper, while the tubes 56 are steel, and the inlet and outlet tanks 12 and 14 are plastic.

In alternative embodiments, a passover tank (not shown) is added to allow the cooling media to pass through two modules 16 before leaving the heat exchanger 10. The passover tank is coupled to one end of the modules 16 and the inlet tank 12 and outlet tank 14 are arranged side by side at the opposite end of the modules 16 as the passover tank. The inlet tank 12 is coupled to half the modules 16 and the outlet tank 14 is coupled to the other half of the modules 16.

In yet other embodiments, the headers 50 may include baffles (not shown). The baffles include structures that extend around select tubes 56. The baffles direct the cooling media through select tubes and not other tubes so that the cooling media passes through two or more modules before leaving the heat exchanger 10.

INDUSTRIAL APPLICABILITY

Heat exchanger 10 may be used in an application such as that illustrated in FIG. 4. An exemplary engine system 76 is used to power a machine 78 or other device. The machine 78 may include on-highway trucks or vehicles, off-highway trucks or machines, earth moving equipment, generators, aerospace applications, marine applications, locomotive applications, pumps, stationary equipment, or other engine powered applications.

The engine system 76 includes one or more engines 80. Engine 80 may be any type of engine (internal combustion, gas, diesel, gaseous fuel, natural gas, propane, etc.), may be of any size, with any number of cylinders, and in any configuration (“V,” in-line, radial, etc.). The engine system 76 further includes an intake 82 for delivering intake air to a compressor 84 of a turbocharger 85. Heated charge air travels from the compressor 84 to an ATAAC 86 through a heated air intake line 88. The ATAAC 86 cools the air prior to entering the engine air intake manifold 90. The air is then used by engine 80, discharged through the engine exhaust manifold 92, and powers the turbine 94 of the turbocharger 85. The engine system 76 may also include other features or systems not shown, such as fuel systems, air systems, aftertreatment systems, peripheries, drivetrain components, etc. and may not include the turbocharger 85 or other components.

The engine 80 is cooled by the cooling media traveling through a radiator input line 96 from the engine's 80 block, through an inlet in a radiator 98, through the radiator 98, out an outlet in the radiator 98, through a radiator output line 100, and back into the engine's 80 block. The cooling media may include glycol, water, air, or any other fluid. A fan 102 may also be used to facilitate heat dissipation. The ATAAC 86 may be mounted in front of or behind the radiator 98 for packaging and to also benefit from the fan 102. The ATAAC 86 may also be mounted entirely separate from radiator 98.

The disclosed heat exchanger 10 may be applied to the intake ATAAC 86 or the radiator 98. The heat exchanger 10 may be used with liquid, air, gas, fuel, fluid, or any other cooling media. Heat exchanger 10 may also be used as a transmission fluid cooler. Heat exchanger 10 may additionally be applied to the cooling of air in an exhaust gas recirculation (EGR) system or clean gas induction (CGI) system.

Heat exchanger 10 is assembled by mounting one of the inlet tank 12 or outlet tank 14 to the engine system 76 or machine 78. The inlet tank 12 or outlet tank 14 is mounted by securing it directly to a structural member, coupling it to a rigid cooling media feed line, or coupling it to the radiator 98 or another heat exchanger. The modules 16 are then inserted into the mounted inlet tank 12 or outlet tank 14 and the seal 68 is formed. Next, the remaining of the inlet tank 12 or outlet tank 14 is added to the other end of the modules 16.

Alternatively, the heat exchanger 10 may also be assembled as a unit separate from the engine system 76 or the machine 78. The modules 16 may be rigidly attached to the inlet tank 12 and outlet tank 14 using bolts, a tight seal, or other fastening means. Tie rods with bolts may also be used extending between the inlet tanks 12 and outlet tank 14 to hold the heat exchanger 10 together as a unit. The inlet tank 12 and outlet tank 14 may also be coupled to a separate frame to form an assembled unit.

A support structure (not shown) may also be added to support the modules 16 that may allow for thermal expansion. Support structure members may be added that extend from the machine 78 frame, engine system 76, or inlet or outlet tanks 12 or 14. A support structure may also be included in the seal lip 38. Structures may also be added to prevent the modules 16 from moving in and out relative to the module apertures 36.

Although the embodiments of this disclosure as described herein may be incorporated without departing from the scope of the following claims, it will be apparent to those skilled in the art that various modifications and variations can be made. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents. 

1. A heat exchanger comprising: an inlet tank including an internal manifold space; a plurality of modules in fluid communication with the inlet tank, the modules including a core having a plurality of tubes, wherein a first end of the tubes terminate in the inlet tank manifold space.
 2. The heat exchanger of claim 1 wherein a cooling media entering the manifold space can enter the tubes by a direct path.
 3. The heat exchanger of claim 1 further including an outlet tank having an internal manifold space, wherein a second end of the tubes terminate in the outlet tank manifold space.
 4. The heat exchanger of claim 1 further comprising the inlet tank including: a first side having a plurality of module apertures for receiving the modules; and a seal lip around the periphery of the module apertures extending at an angle from the first side of the inlet tank, wherein the seal lip is configured to form a seal between the seal lip and the module.
 5. The heat exchanger of claim 4 wherein the seal lip extends into the manifold space and at an angle substantially perpendicular to the first side of the inlet tank.
 6. The heat exchanger of claim 1 further including: a header coupled to at least one of a first and second end of the core, wherein the header includes: a base coupled to the core; and a boss around a periphery of the base extending at an angle from the base to form a seal between the periphery of the boss and the inlet tank.
 7. The heat exchanger of claim 6 wherein the boss includes a seal slot and a seal ring disposed at least partially inside the seal slot to form the seal.
 8. A heat exchanger comprising: an inlet tank including a first side; a plurality of modules in fluid communication with the inlet tank; a plurality of module apertures in the first side of the inlet tank for receiving the modules; a seal lip around the periphery of at least one of the module apertures and extending at an angle to the first side; and a seal formed between the seal lip and the module.
 9. The heat exchanger of claim 8 wherein the module includes a first end received in the inlet tank and a second end opposite the first end, the second end received in an outlet tank.
 10. The heat exchanger of claim 9 wherein the module includes a core having a first and second end, and a header coupled to at least one of the first and second end.
 11. The heat exchanger of claim 10 wherein the header includes a base coupled to the core and a boss around a periphery of the base and extending at an angle from the base, the boss configured to form the seal between the periphery of the boss and the inlet tank.
 12. The heat exchanger of claim 11 wherein the boss includes a seal slot and a seal ring disposed at least partially inside the seal slot to form the seal.
 13. The heat exchanger of claim 10 wherein the core includes a plurality of radiator fins and a plurality of tubes extending between the first and second ends.
 14. The heat exchanger of claim 8 wherein the inlet tank includes: a second side opposite the first side; a first wall; a second wall opposite the first wall; a third wall; and a fourth wall opposite the third wall wherein, the third wall and fourth wall interconnect the first side, second side, first wall, and second wall to form a box structure with an internal manifold space.
 15. The heat exchanger of claim 11 wherein the seal lip extends at an angle substantially perpendicular from the first side of the inlet tank and into a internal manifold space the inlet tank and the boss extends at an angle substantially perpendicular to the base and into the manifold space.
 16. A module for a heat exchanger comprising: a core having a first end; a second end opposite the first end; and a header coupled to at least one of the first and second end, the header including: a base coupled to the core; and a boss around a periphery of the base extending at an angle to the base, wherein the boss is configured to form a seal between the periphery of the boss and a tank.
 17. The module of claim 16 wherein the boss extends substantially perpendicular to the base and includes a seal slot in an outer seal surface and a seal ring to form the seal.
 18. The module of claim 16 wherein the header is inserted into one of a plurality of module apertures in the tank.
 19. The module of claim 18 wherein the seal is formed between the periphery of the boss and a seal lip extending to the periphery of the module apertures in the tank.
 20. The module of claim 16 wherein the core includes a plurality of radiator fins and a plurality of tubes extending between the first end and second end. 